Air Distribution Housing
HOUSING-AIR DISTRIBUTION
WARNING: The heater core tubes are not serviced separately from the heater core. The heater core tubes should not be repositioned, loosened or removed from the heater core. Failure to follow this warning could result in a coolant leak and possible personal injury or death.
NOTE: LHD model shown in illustrations. RHD model similar.
NOTE: If the seal on any air door is deformed or damaged, that air door must be replaced.
1. Install the floor-air door (1), blend-air door (2), panel-air door (3) and the defrost-air door (4) into the driver side of the air distribution housing (5) as required. Align the air door pivot shafts with the holes in the housing.
2. Install the air deflector vane assembly (1) into the passenger side of the air distribution housing (2). Slide the vane assembly into the track in the housing and engage the two plastic retaining tabs. Make sure the retaining tabs are fully engaged.
3. Align the air door pivot shafts with the holes in the passenger side of the air distribution housing (3) and carefully install passenger side of the air distribution housing (1) onto the driver side of the housing.
4. Engage the four plastic retaining tabs (4) that secure the two halves of the air distribution housing together. Make sure the retaining tabs are fully engaged.
5. Install the retaining screw (5) that secures the two halves of the air distribution housing together at the bottom of the housing, near the center. Tighten the screw to 1.2 Nm (10 in lbs.).
NOTE: If the foam seal on top of the air distribution housing is deformed or damaged, it must be replaced.
6. Inspect the foam seal (1), especially along the parting line (2) of the two halves of the air distribution housing. Replace the seal if it is deformed or damaged.
NOTE: If the foam insulator around the heater core is deformed or damaged, the insulator must be replaced.
7. Carefully install the heater core (2) into the passenger side of the air distribution housing (3) and engage the four plastic retainer tabs (1) that secure the heater core to the housing. Make sure the retaining tabs are fully engaged.
8. Position the heater core tube flange (4) over the heater core tubes (6) and onto the to the passenger side of the air distribution housing (8).
9. Engage the plastic retainer (5) around the heater core tubes. Make sure the retainer is fully engaged.
10. Install the screw (2) that secures the heater core tube flange to the air distribution housing. Tighten the screw to 1.2 Nm (10 in lbs.).
11. Install the upper front passenger side floor duct (7) onto the air distribution housing and install the two retaining screws (1). Tighten the screws to 1.2 Nm (10 in lbs.).
NOTE: If the foam seal for the heater core tube flange is deformed or damaged, it must be replaced.
12. Install the foam seal (3) onto the heater core tube flange.
13. If equipped with the 2.8L diesel engine, install the electric positive temperature coefficient (PTC) heater unit.
14. Install the blend door cam (5), blend door lever (6), blend door gear (4), panel door gear (3), mode door cam (2), and the defrost door lever and gear assembly (1) onto the driver side of the air distribution housing (7).
15. Install the driver side front floor duct (7) onto the driver side of the air distribution housing (4) and install the two retaining screws (8). Tighten the screws to 1.2 Nm (10 in lbs.).
16. Position the actuator mounting bracket (5) onto the air distribution housing and install the three retaining screws (1). Tighten the screws to 1.2 Nm (10 in lbs.).
17. Position the mode door actuator (2) and the blend door actuator (6) onto the actuator mounting bracket. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those on the door linkage.
18. Install the screws (3) that secure the mode and blend door actuators to the actuator mounting bracket. Tighten the screws to 1.2 Nm (10 in lbs.).
19. Install the air distribution housing onto the HVAC housing.
20. Install the HVAC housing assembly.